Browse Topic: Drilling
ABSTRACT Ground vehicles are complex systems with many interrelated subsystems - finding the sweet-spot among competing objectives such as performance, unit cost, O&S costs, development risk, and growth potential is a non-trivial task. Whole Systems Trade Analysis (WSTA) is a systems analysis and decision support methodology and tool that integrates otherwise separate subsystem models into a holistic system view mapping critical design choices to consequences relevant to stakeholders. As a highly integrated and collaborative effort WSTA generates a holistic systems and Multiple Objective Decision Analysis (MODA) model. The decision support model and tool captures and synthesizes outputs from individual analyses into trade-space visualizations designed to facilitate rapid and complete understanding of the trade-space to stakeholders and provide drill down capability to supporting rationale. The approach has opened up trade space exploration significantly evaluating up to 1020+ potential
The Electroimpact Automatic Fan Cowl Riveter exhibits new and unique design features and automated process capabilities that address and overcome three primary technical challenges. The first challenge is satisfying the customer-driven requirement to access the entire fastening area of the fan cowl doors. This necessitates a unique machine design which is capable of fitting ‘inside’ a fan cowl door radius. The second challenge is determining drill geometry and drill process parameters which can produce consistent and high-quality countersunk holes in varying mixed-metal stack-up combinations consisting of aluminum, titanium, and stainless steel. The third challenge is providing the capability of fully automatic wet installation of hollow-ended titanium rivets. This requires an IML-side countersinking operation, depositing sealant throughout the OML and IML countersinks and the hole, automatically feeding and inserting a rivet which is only 5mm long and 6mm in head diameter and flaring
In numerous industries such as aerospace and energy, components must perform under significant extreme environments. This imposes stringent requirements on the accuracy with which these components are manufactured and assembled. One such example is the positional tolerance of drilled holes for close clearance applications, as seen in the “EN3201:2008 Aerospace Series – Holes for metric fasteners” standard. In such applications, the drilled holes must be accurate to within ±0.1 mm. Traditionally, this required the use of Computerised Numerical Control (CNC) systems to achieve such tight tolerances. However, with the increasing popularity of robotic arms in machining applications, as well as their relatively lower cost compared to CNC systems, it becomes necessary to assess the ability of robotic arms to achieve such tolerances. This review paper discusses the sources of errors in robotic arm drilling and reviews the current techniques for improving its accuracy. The main sources of
This SAE Aerospace Standard (AS) provides general information for the interpretation and clarification of engineering drawing requirements relating to the manufacture and inspection of fluid system couplings, tube fittings, and hose ends. Because it is impractical to define every minute detail of the part on the face of the drawing, this standard describes interpretations of dimensioning of general machining features and otherwise undefined tolerances that fall under the heading of “good shop practice.” This standard is supplemental to ASME Y14.5M-1994 and explains, defines, and interprets drawing terms or practices that are not addressed by ASME Y14.5M-1994. Unless otherwise specified in this standard, drawing interpretations contained in ASME Y14.5M-1994 shall apply
Traditional solutions developed for the aerospace industry must overcome challenges posed for automation systems like design, requalification, large manual content, restricted access, and tight tolerances. At the same time, automated systems should avoid the use of dedicated equipment so they can be shared between jigs; moved between floor levels and access either side of the workpiece. This article describes the development of a robotic system for drilling and inspection for small aerostructure manufacturing specifically designed to tackle these requirements. The system comprises three work packages: connection within the digital thread (from concept through to operational metrics including Statistical Process Control), innovative lightweight / low energy drill, and auto tool-change with in-process metrology. The validation tests demonstrating Technology Readiness Level 6 are presented and results are shown and discussed
Efforts toward the mechanization of aircraft manufacturing began as a divided focus between devices like power tools that augment human worker capability and purpose-designed, “monument” automation. While both have benefits and limitations, the capability of modern industrial robots has grown to the point of being able to effectively fill the capability gap between them, offering a third option in the mechanization toolbox. Moreover, increasing computer processing power continues to enable more advanced approaches to perception to inform task planning and execution. Higher performance robots supplemented with greater ability to adapt to various conditions and scenarios have also led to the ability to operate reliably and safely outside traditional fixed-installation, caged work cells. This in turn has made it feasible for robot systems to work in ever more complex environments and applications, including the world of aircraft assembly with its numerous challenges like workpiece scale
As the aerospace industry moves toward determinate assembly and ever-tighter manufacturing tolerances, there is a need for automated, high-precision milling, trimming and drilling equipment that is specialized for aerospace applications. Precision countersinking is a common requirement for aircraft parts, but this is not a process that typical general-purpose milling machines are able to accommodate without the use of specialty tools such as depth-stop tool holders. To meet this need, Electroimpact has designed a 5-axis milling machine with high-speed clamping capability for countersink depth control. A custom trunnion and head with a quill and an additional clamp axis provide clamping functionality similar in speed and precision to a riveting machine, while maintaining the accuracy and features of a conventional machining center. An additional focus on design for pre-compensation accuracy has allowed the system to achieve post-compensation path and positioning tolerances that are
Using the Box Behnken experimental design, this research work gives a thorough mathematical model for predicting the effects of drilling parameters on the delamination factor during the drilling of CFRP/Al stacked composites. These composites are commonly utilized in aerospace applications and are frequently subjected to drilling for assembling purpose. The goal of this study is to predict the drilling parameters like drill type, drill diameter, feed rate and spindle speedthat affect the amount of delamination which occurs when drilling such composites. During the drilling operation, damage was noticed on the surface of the fabricated composite laminates. The experiments were conducted according to the Box Behnken experimental design and delamination response is measured by using an image processing software. It is concluded that among all the parameters, the feed rate influences more on the delamination factor
In significant industrial segments across the globe, there continues to be major investment in large-scale equipment that incorporates heavy-duty material movement and handling systems. In mining applications such as bucket wheel excavators and conveyors, to metal shredders in recycling operations, as well as winch systems and drilling equipment in offshore applications, powerful low-speed drives that can deliver high torque and reliably function in rugged demanding environments are in high demand
The usage of AZ91E series magnesium alloy material increases in the field of automobile, aerospace and structural applications because of its enhanced mechanical properties, light weight and good machinability characteristics. The present investigation is to optimize the drilling process parameters of magnesium alloy (AZ91E) hybrid nano composite consisting of chopped basalt fiber (9wt%) and SiCp (7.5wt%) fabricated by vacuum stirring technique. AZ91E hybrid nano composite is drilled by M-Tab vertical machining centre equipped with CNC under dry state (without coolant). The dry state drilling operation was performed by HSS tool with varied input parameters like drill diameter (6mm, 8mm, 10mm and 12mm), spindle speed (200rpm, 300rpm 400rpm 500rpm), feed rate (5mm/min, 10mm/min, 15 mm/min, 20 mm/min) with constant depth of cut (15mm). The effect of machining time, metal removal rate and surface roughness is evaluated and optimum level of drilling parameters is determined through Taguchi
The Inconel 718 is an alloy based on nickel of high thermal and mechanical resistance, which allows its wide application in the aerospace industry, being generally implemented in aircraft tail cone and engine components. On the other hand, these features become a recurring problem when the machining of this material is performed. For example, in the drilling process of this superalloy, the cutting tools used exhibit excessive wear due to the high temperature and pressure at the cutting edge. However, there are numerous parameters that can influence the cutting tool life, and when analyzed and well defined, determine the types of modifications needed to enable less wear, and consequently an increase of its useful life in service. Given this context and knowing that the study of tool life in the Inconel 718 drilling process is extremely relevant in the aerospace sector, this paper presents a wear study in order to evaluate the behavior of different types of cutting tools used to drill
Design and production of an assembly system for a major aircraft component is a complex undertaking, which demands a large-scale system view. Electroimpact has completed a turnkey assembly line for producing the wing, flap, and aileron structures for the COMAC C919 aircraft in Xi’an, China. The project scope includes assembly process design, material handling design, equipment design, manufacture, installation, and first article production support. Inputs to the assembly line are individual component parts and small subassemblies. The assembly line output is a structurally completed set of wing box, flaps, and ailerons, for delivery to the Final Assembly Line in Shanghai. There is a trend toward defining an assembly line procurement contract by production capacity, versus a list of components, which implies that an equipment supplier must become an owner of production processes. The most significant challenge faced was the amount of front end engineering work required to develop
This SAE Standard covers complete general and dimensional specifications for refrigeration tube fittings of the flare type specified in Figures 1 to 42 and Tables 1 to 15. These fittings are intended for general use with flared annealed copper tubing in refrigeration applications. Dimensions of single and double 45 degree flares on tubing to be used in conjunction with these fittings are given in Figure 2 and Table 1 of SAE J533. The following general specifications supplement the dimensional data contained in Tables 1 to 15 with respect to all unspecified details
This SAE Recommended Practice provides a systematic method for the identification of single diameter drills. It is intended to assist in the cataloging and supplying of these tools. NOTE 1— Caution must be taken when assigning codes for designators to prevent specifying drills that cannot be physically or economically manufactured. NOTE 2— In particular without limitation, SAE disclaims all responsibility for the accuracy or completeness of information contained within this report if the standards of this report are retrieved, combined, or used in connection with any software
This SAE Recommended Practice provides a systematic method for the identification of multiple diameter cutting tools. It is intended to assist in the cataloging and supplying of these tools. NOTE 1— Caution must be taken when assigning codes for designators to prevent specifying cutting tools that cannot be physically or economically manufactured. NOTE 2— In particular without limitation, SAE disclaims all responsibility for the accuracy or completeness of information contained within this report if the standards of this report are retrieved, combined, or used in connection with any software
With air traffic demand constantly increasing and several years of aircraft production in their backlog, major aircraft manufacturers are now shifting their focus toward improving assembly process efficiency. One of the most promising solutions, known as “One Side Assembly”, aims to perform the whole assembly sequence from one side of the structure (drilling, temporary fastener installation and removal, blind fastener installation, assembly control) and with a high level of integrated automation. Investments in robotic equipment, automation engineering and innovation are very active and automation capabilities have already increased a lot in the aerospace industry. As an example, drilling operations for large dimensions airframe are clearly moving from manual to automated. However, despite more and more clever and sophisticated robotics, the use of historical fasteners with two side installation method remains a strong limitation to innovative automated assembly sequences. A blind
This SAE Aerospace Standard (AS) provides minimum design, hole preparation, installation and removal requirements for AS3272, AS3273, MA3274, and MA3275 serrated shank self-locking clinch nuts. This standard is applicable when specified on engineering drawings or in procurement documents
One way assembly of aero structures has the potential to significantly reduce build times. One of the solutions, which goes towards achieving this philosophy, is the use of a ‘C’ clamping automated drilling system. The Manufacturing Technology Centre has developed and manufactured a ‘C’ clamping automated drilling unit to overcome many of the limitations of current designs, which prevent their use on a broader range of structures. The drilling unit addresses issues with access, size and weight restrictions as well as economic factors. This technical paper will present the outcomes from the design and manufacture of the drilling unit that is to be used within restricted access areas, as either a hand held device or as a robotic end effector free from any cables or hoses, allowing full and unhindered articulation of any robot motion. The device’s services: power, tool lubrication, swarf extraction and control systems have been designed to be embedded, rendering it a standalone unit. With
Electroimpact has developed a system for drilling and fastening of cargo door structures which efficiently addresses many of the manufacturing challenges that such parts present. Challenges to door automation include 1) the presence of an inner skin that must be processed, in addition to the outer skin, and 2) a stiff frame structure, which makes the clamping and drilling processes that are typical to automated fastening machines very unforgiving of any errors in workpiece positioning. In this case, the manufacturing cell was to be installed in an existing facility with very limited ceiling height, further complicating the system and process design. New methods were devised to solve these problems, and the solutions found will likely have utility in future applications
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